Corner assembly for vehicle

Abstract

In a first aspect, the invention is directed to a wheel assembly for a vehicle, including a non-rotating support member, a wheel and an electric motor. Loads incurred during vehicle use can cause dynamic flexing of portions of the wheel. The wheel assembly in accordance with the first aspect of the invention has a load path for loads incurred by the wheel that passes from the wheel to the non-rotating support member without passing through the motor, thereby reducing a potential source of distortion of the gap in the motor (between the motor's rotor and stator) during the aforementioned flexing.

1 . A wheel assembly for a vehicle, comprising:
 a non-rotating support member;   a wheel including a rim, a spider and a wheel hub, the rim having a radially inner surface, wherein the wheel is rotatably supported by the non-rotating support member for rotation about a wheel axis;   an electric motor having an axially extending motor aperture, wherein the electric motor includes a non-rotating motor portion and a rotating motor portion, wherein the rotating motor portion is operatively connected to the wheel and is spaced from the radially inner surface of the rim for substantial isolation from any radially inwardly directed forces from the radially inner surface of the rim, wherein the non-rotating motor portion is fixedly connected to the non-rotating support member; and   a gearbox that is driven by the rotating motor portion and that drives the wheel, wherein the gearbox is spaced from the radially inner surface of the rim for substantial isolation from any radially inwardly directed forces from the radially inner surface of the rim.   
     
     
         2 . A wheel assembly as claimed in  claim 1 , wherein the wheel is supported by the non-rotating support member through a first wheel bearing and a second wheel bearing, and the motor is supported by the non-rotating support member through a first motor bearing and a second motor bearing. 
     
     
         3 . A wheel assembly as claimed in  claim 1 , wherein the non-rotating support member includes a spindle and a knuckle, wherein the spindle is axially outboard of the knuckle, wherein the non-rotating portion of the motor is connected to the knuckle, and the wheel is supported by the spindle. 
     
     
         4 . A wheel assembly as claimed in  claim 1 , wherein the rotating motor portion is connected to the wheel through the wheel hub. 
     
     
         5 . A wheel assembly as claimed in  claim 1 , wherein the rotating motor portion is spaced from the radially inner surface of the rim by an air gap. 
     
     
         6 - 11 . (canceled) 
     
     
         12 . A drive assembly for a vehicle, comprising:
 A non-rotating support member;   an electric motor supported by the non-rotating support member and having a non-rotating motor portion and a rotating motor portion;   a wheel rotatably supported by the non-rotating support member; and   a gearbox having at least two selectable ratios associated therewith, wherein the electric motor is operatively connected to the gearbox, and wherein the gearbox is operatively connected to the wheel,   wherein the gearbox includes a first stage and a second stage, wherein the first stage includes a first stage input member drivable by the rotating motor portion and a first stage output member drivable by the first stage input member, and the second stage includes a second stage output member, wherein the first stage output member is movable between a first position and a second position, wherein in the first position the first stage output member is operatively connected to the wheel such that the wheel is driven by the first stage output member without being driven by the second stage, and wherein in the second position the first stage output member is operatively connected to the second stage output member and the second stage output member is operatively connected to the wheel.   
     
     
         13 . A drive assembly as claimed in  claim 12 , wherein the wheel includes a hub having a first input drive connector and a second input drive connector, wherein, in the first position the first stage output member is operatively connected to the first input drive connector and in the second position the second stage output member is operatively connected to the second input drive connector. 
     
     
         14 . A drive assembly as claimed in  claim 12 , wherein the first stage input member includes a sun gear and wherein the first stage further includes a plurality of first stage planet gears, a first stage ring gear and a first stage planet carrier, wherein the first stage output member is slidable axially between the first position and the second position, and is rotatable by the first stage planet carrier in both the first and second positions. 
     
     
         15 . A drive assembly as claimed in  claim 14 , wherein the second stage includes a plurality of second stage planet gears, a second stage ring gear and a second stage planet carrier that is the second stage output member, wherein in the second position the first stage output member is a second stage sun gear for the second stage planet gears. 
     
     
         16 - 42 . (canceled) 
     
     
         43 . A method of assembling a wheel assembly, comprising:
 (a) Providing a non-rotating support member having a non-rotating support member axis;   (b) providing an electric motor, wherein the electric motor includes a rotating motor portion and a non-rotating motor portion including a motor housing, wherein the rotating motor portion is rotatably supported on the motor housing, wherein the electric motor has an axially extending motor aperture defined by the motor housing;   (c) axially sliding the electric motor onto the non-rotating support member, such that the non-rotating support member passes through the motor aperture and supports the motor housing;   (d) Fixing the non-rotating motor portion to the non-rotating support member;   (e) Providing a gearbox having at least one gearbox input member and at least one gearbox output member;   (f) Axially sliding the gearbox onto the non-rotating support member, such that the at least one gearbox input member and the at least one gearbox output member are rotatable relative to the non-rotating support member;   (g) operatively connecting the rotating motor portion to the at least one gearbox input member;   (h) axially sliding a wheel onto the non-rotating support member such that the non-rotating support member rotatably supports the wheel; and   (i) operatively connecting the at least one gearbox output member to the wheel.   
     
     
         44 . A method of assembling a wheel assembly as claimed in  claim 43 , wherein the wheel includes a wheel hub, a spider and a rim, wherein the wheel spider is removably connectable to the wheel hub. 
     
     
         45 . A method of assembling a wheel assembly as claimed in  claim 44 , wherein step (h) includes:
 (j) axially sliding the wheel hub onto the non-rotating support member in such a way that the non-rotating support member rotatably supports the wheel hub;   (k) operatively connecting the at least one gearbox output member to the wheel hub;   (l) axially bringing a brake rotor into engagement with the wheel hub;   (m) axially sliding the spider and rim onto the wheel hub so that the wheel hub supports the spider and rim after step (l);   (n) axially driving a plurality of brake rotor mounting fasteners into engagement with the brake rotor and the wheel hub to fix the brake rotor to the wheel hub;   (o) axially driving a plurality of spider mounting fasteners into engagement with the spider and the wheel hub to fix the spider to the wheel hub; and   (p) mounting a brake caliper to a non-rotating member such that the brake caliper is operable to stop rotation of the brake rotor.   
     
     
         46 . A method of assembling a wheel assembly as claimed in  claim 45 , wherein the brake rotor mounting fasteners and the spider mounting fasteners are the same, and steps (n) and (o) occur simultaneously and include axially driving the said same fasteners into engagement with the brake rotor, the wheel hub and the spider to fix the spider and the brake rotor to the wheel hub. 
     
     
         47 . A method of assembling a wheel assembly as claimed in  claim 46 , wherein steps (l), (m), (n) and (o) are carried out prior to carrying out step (j). 
     
     
         48 . A method of assembling a drive assembly as claimed in  claim 43 , wherein the non-rotating motor portion includes a stator and a motor housing that includes a radially outer housing portion and a radially inner housing portion that is fixedly connected to the radially outer housing portion, wherein the rotating motor portion is rotatably supported on the radially inner housing portion. 
     
     
         49 - 50 . (canceled)